Closed loop recycling system and dip tank for antimicrobial compounds

ABSTRACT

A dip tank and recycling system for applying antimicrobial solution to food items, including a dip tank having a bottom and sides, and holding a liquid antimicrobial solution. A conveyor to convey food items through the tank passes through the liquid antimicrobial solution held in the tank such that food items conveyed on the conveyor are dipped in the liquid antimicrobial solution. At least two discharge nozzles spray fresh antimicrobial solution into the tank. The discharge nozzles are located in the sides of the tank, and are positioned above the level of the conveyor but below an expected top level of the liquid antimicrobial solution contained within the tank such that food items conveyed on the conveyor are agitated by the force of the spray from the discharge nozzles. The spray from the discharge nozzles causes unstacking of items on the conveyor, producing an even application of the antimicrobial solution.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of U.S. patent application Ser. No.14/679,546 filed Apr. 6, 2015, which is a Continuation of pending U.S.patent application Ser. No. 14/510,439, filed Oct. 9, 2014, thedisclosures of which are incorporated herein by reference for allpurposes.

BACKGROUND

The present disclosure relates to a closed loop recycling system and diptank for antimicrobial compounds, typically used in connection with foodprocessing.

Recycling of antimicrobial liquids that are applied to some types offood products, such as poultry parts, presents a number of specialissues, particularly concerning adulteration, contamination, andcross-contamination. U.S. patent application Ser. No. 11/409,514, filedApr. 21, 2007, titled “Application System with Recycle and Related Useof Antimicrobial Quaternary Ammonium Compound”, the entire contents ofwhich are herein incorporated by reference, seeks to address some ofthese issues with an antimicrobial application system and recycle unit.

SUMMARY

In one arrangement, this disclosure relates to a dip tank forapplication of antimicrobial solution to food items, the dip tankincluding a tank having a bottom and sides, the tank holding a liquidantimicrobial solution therein. A conveyor to convey food items throughthe tank is included, the conveyor passing through the liquidantimicrobial solution held in the tank such that food items conveyed onthe conveyor are dipped in the liquid antimicrobial solution. At leasttwo discharge nozzles are provided for spraying fresh antimicrobialsolution into the tank, the discharge nozzles being located in the sidesof the tank, and positioned above the level of the conveyor but below anexpected top level of the liquid antimicrobial solution contained withinthe tank such that food items conveyed on the conveyor are agitated bythe force of the spray from the discharge nozzles. A drain is alsoincluded for draining and recycling antimicrobial solution from thetank.

The use of conveyors in the processing of meat products can result instacking of the product. If an antimicrobial solution is applied tostacked products, there is the risk that some surfaces of the productmay not receive an adequate amount of the antimicrobial solution. Thesubmerged discharge nozzles placed above the belt and below the surfaceof the liquid in the dip tank causes the unstacking of products on theconveyor and therefore allows for an even application of theantimicrobial solution.

In certain arrangements, the same number of discharge nozzles can beprovided on each side of the tank, for example, four discharge nozzlescan be provided on each side of the tank. The discharge nozzles can bearrayed along a direction of travel of food items on the conveyor.

In some arrangements, the drain can be located on the bottom of thetank, whereas in other arrangements, the drain can be located in a sideof the tank. The drain may be provided in a suction box attached to aside of the tank, and an aperture can be provided in the side of thetank for ingress of the antimicrobial solution into the suction box. Afilter screen can be provided between the suction box and the tank, thefilter screen at least partially covering the aperture in the side ofthe tank. The filter screen can include a plurality of rods having agenerally circular cross-section. The filter screen does not extend tothe top of the aperture in some arrangements.

The suction box can further include at least one sensor to measure alevel of antimicrobial solution in the tank. The sensor can be apressure transducer located in the bottom of the suction box.

In one arrangement, the dip tank includes an outlet section comprising adrip pan positioned to catch antimicrobial solution that drips from thefood items after exiting the tank. The dip tank may also include a stopdrip pan. The stop drip pan may be positioned to isolate a rinsesolution that is applied to the food items in a rinse application afterpassing through the dip tank from the antimicrobial solution that iscaught in the drip pan.

Also disclosed herein is a method of applying antimicrobial solution tofood items. The method can include providing a tank having a bottom andsides, and filling the tank with a liquid antimicrobial solution to adesignated level within the tank. Food items, such as poultry parts, canbe conveyed through the tank with a conveyor that is submerged in theliquid antimicrobial solution held in the tank, such that the food itemsconveyed on the conveyor are dipped in the liquid antimicrobialsolution. The method also includes spraying fresh antimicrobial solutioninto the tank through discharge nozzles located in the sides of thetank. The discharge nozzles are positioned above the level of theconveyor but below the top level of the liquid antimicrobial solutioncontained within the tank, such that food items conveyed on the conveyorare agitated by the force of the spray from the discharge nozzles. Theantimicrobial solution can be drained from the tank and recycled.

In some arrangements of the method, the discharge nozzles can be arrayedalong a direction of travel of food items on the conveyor, and the sprayfrom each discharge nozzle agitates the food items in turn. The liquidantimicrobial solution can be a solution containing cetylpyridiniumchloride.

In one aspect, the method includes catching in a drip pan antimicrobialsolution that drips from the food items after the food items exit thetank and recycling the antimicrobial solution caught in the drip pan.The method may also include isolating with a stop drain pan a rinsesolution applied to the food items during a rinse application from theantimicrobial solution.

The antimicrobial solution can be drained from the tank and continuouslyfiltered and recycled to the discharge nozzles. In some arrangements,the antimicrobial solution drained from the tank can be filtered using arotary screen filter.

A suction box for withdrawing liquid antimicrobial solution from a diptank is also described herein, the suction box having a bottom and atleast three side walls, and being at least partially open at a fourthside for attachment to an aperture located in a side wall of a tank. Thesuction box can include a filter screen in the at least partially openside for at least partially covering the aperture in the side of thetank, and a drain opening that is attachable to a suction pump forwithdrawing liquid therethrough.

The filter screen can comprise a plurality of rods having a generallycircular cross-section. In some arrangements, the filter screen may notextend to the top of the aperture located in the side wall of the tank.

At least one sensor can be included in the suction box to measure alevel of antimicrobial solution in the tank. The sensor can be apressure transducer located in the bottom of the suction box.

In another aspect of this disclosure, a rotary screen filter forfiltering particulates from a liquid is included. The rotary screenfilter can comprise a rotary drum having a screen, mesh or aperturedfilter portion and at least one solid portion having no aperturestherein. At least one spray nozzle can be located above the rotary drumfor spraying clean liquid onto the drum surface. An inlet spout can beprovided for entry of liquid containing particulates, the inlet spoutbeing located in the interior of the rotary drum. The inlet spout candischarge liquid onto the solid portion of the rotary drum. A collectiontank can be located underneath the rotary drum for collecting fluidfiltered by the filter portion. A screw impeller can be provided on theinterior of the rotary drum, such that rotation of the drum causes solidparticulates remaining in the drum to be impelled to an end of the drumfor collection.

The at least one solid portion of the rotary drum can define a rimportion of the drum. The collection tank can further include at leastone drain and conduit for recycling the collected filtered fluid.

The screw impeller can be formed of a band positioned perpendicular toan inner surface of the screen portion, and extending around the innersurface of the screen portion in a spiral.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an antimicrobial application andrecycling system according to the present disclosure.

FIG. 2 is a first side view of the system of FIG. 1.

FIG. 3 is a second side view of the system of FIG. 1.

FIG. 4 is a top view of the system of FIG. 1.

FIG. 5 is a bottom view of the system of FIG. 1.

FIG. 6 is an end view of the system of FIG. 1.

FIG. 7 is another end view of the system of FIG. 1.

FIG. 8 is a perspective view of an alternative arrangement of dip tankand suction box for use in an antimicrobial application and recyclingsystem according to the present disclosure.

FIG. 9 is a detail view of the suction box of FIG. 8.

FIG. 10 is a sectional view of the dip tank and suction box of FIG. 8.

DETAILED DESCRIPTION

Various embodiments are described and illustrated in this specificationto provide an overall understanding of the composition, function,operation, and application of the disclosed system, apparatus andmethods. It is understood that the various embodiments described andillustrated in this specification are non-limiting and non-exhaustive.Thus, the invention is not necessarily limited by the description of thevarious non-limiting and non-exhaustive embodiments disclosed in thisspecification. The features and characteristics illustrated or describedin connection with various embodiments may be combined with the featuresand characteristics of other embodiments. Such modifications andvariations are intended to be included within the scope of thisspecification. As such, the claims may be amended to recite any featuresor characteristics expressly or inherently described in, or otherwiseexpressly or inherently supported by, this specification. Further,Applicant reserves the right to amend the claims to affirmativelydisclaim features or characteristics that may be present in the priorart. Therefore, any such amendments comply with the requirements of 35U.S.C. §§ 112(a) and 132(a). The various embodiments disclosed anddescribed in this specification can comprise, include, consist of, orconsist essentially of the features and characteristics as variouslydescribed in this specification.

Also, any numerical range recited in this specification is intended toinclude all sub-ranges of the same numerical precision subsumed withinthe recited range. For example, a range of 1.0 to 10.0 is intended toinclude all sub-ranges between (and including) the recited minimum valueof 1.0 and the recited maximum value of 10.0, that is, having a minimumvalue equal to or greater than 1.0 and a maximum value equal to or lessthan 10.0, such as, for example, 2.3 to 6.6. Any maximum numericallimitation recited in this specification is intended to include alllower numerical limitations subsumed therein and any minimum numericallimitation recited in this specification is intended to include allhigher numerical limitations subsumed therein. Accordingly, Applicantreserves the right to amend this specification, including the claims, toexpressly recite any sub-range subsumed within the ranges expresslyrecited in this specification. All such ranges are intended to beinherently described in this specification such that amending toexpressly recite any such sub-ranges would comply with the requirementsof 35 U.S.C. §§ 112(a) and 132(a).

Any patent, publication, or other disclosure material identified in thisspecification is incorporated by reference into this specification inits entirety unless otherwise indicated, but only to the extent that theincorporated material does not conflict with existing descriptions,definitions, statements, or other disclosure material expressly setforth in this specification. As such, and to the extent necessary, theexpress disclosure as set forth in this specification supersedes anyconflicting material incorporated by reference into this specification.Any material, or portion thereof, that is said to be incorporated byreference into this specification, but which conflicts with existingdefinitions, statements, or other disclosure material set forth in thisspecification, is only incorporated to the extent that no conflictarises between that incorporated material and the existing disclosurematerial. Applicants reserve the right to amend this specification toexpressly recite any subject matter, or portion thereof, incorporated byreference into this specification.

The grammatical articles “one”, “a”, “an”, and “the”, as used in thisspecification, are intended to include “at least one” or “one or more”,unless otherwise indicated. Thus, the articles are used in thisspecification to refer to one or more than one (i.e., to “at least one”)of the grammatical objects of the article. By way of example, “acomponent” means one or more components, and thus, possibly, more thanone component is contemplated and may be employed or used in animplementation of the described embodiments. Further, the use of asingular noun includes the plural, and the use of a plural noun includesthe singular, unless the context of the usage requires otherwise.Additionally, the grammatical conjunctions “and” and “or” are usedherein according to their accepted usage. By way of example, “x and y”refers to “x” and “y”. On the other hand, “x or y” refers to “x”, “y”,or both “x” and “y”, whereas “either x or y” refers to exclusivity.

In the processing of meat, and particularly in the processing of poultrysuch as chicken, sanitation of the food products and equipment duringprocessing is extremely important. As herein described, an antimicrobialapplication system or methods may be employed to apply an antimicrobialsolution, e.g., by spraying or dipping the food products to beprocessed, such as raw meat or chicken parts to reduce microbialcontaminants on the meat. As herein described, an antimicrobialapplication system may be configured to recycle antimicrobial solutionsused in connection with food processing. The recycling may includerecycling of antimicrobial solution applied to items associated withfood processing for subsequent application of the recycled antimicrobialsolution to items associated with food processing. The antimicrobialapplication system may include an antimicrobial application unit and arecycle unit. An initial, dilute antimicrobial composition may beprepared and the concentration of the antimicrobial may be controlledautomatically by a control unit. The control unit may include or beoperatively controllable by a processor. The processor may be configuredto access a data storage medium having stored therein instructionsexecutable by the processor to perform one or more operations of theantimicrobial application system. The antimicrobial composition may beprovided to the antimicrobial application unit and applied to workpieces, such as raw poultry carcasses. After application to the workpieces, the antimicrobial composition-containing solution may flow to arecycle tank of the recycle unit. The concentration of the antimicrobialin the antimicrobial solution flowing to the recycle tank may bemonitored manually or by the system. Additional antimicrobial may beautomatically added if the concentration of the antimicrobial in theantimicrobial solution falls below a desired amount. Additionalantimicrobial may also be automatically added at a rate thatapproximates the rate at which the antimicrobial is depleted from thesolution. All or a portion of the antimicrobial solution may beperiodically diverted to a capture tank for selective removal of theantimicrobial composition from the solution. The removed antimicrobialand remaining solution are then disposed of in appropriate manners. Theantimicrobial is preferably a quaternary ammonium compound, analkylpyridinium chloride, or cetylpyridinium chloride. Various differentantimicrobial solutions are suitable for use, including, for example, asolution containing cetylpyridinium chloride (CPC). One suitableantimicrobial solution is available under the name Cecure from SafeFoods Corporation.

Referring to FIGS. 1-7, reference numeral 10 refers in general to anarrangement of an antimicrobial application system according to thepresent disclosure. Although exemplary dimensions are given below forvarious components of the system, it should be appreciated that thecomponents can be customized for different processing plants, and aretherefore not intended to be limiting.

In various embodiments, the antimicrobial application system 10 may bepart of a meat processing system employed by a producer or processor ofmeat. The antimicrobial system 10, for example, may be housed within alarger meat processing plant (not shown) with additional processingapparatuses or devices associated with the meat processing system. Thesystem 10 generally comprises an antimicrobial application unit 12configured to apply an antimicrobial solution to workpieces, such as rawmeat or poultry carcasses or pieces. In some configurations, theantimicrobial application system 10 may further include or be configuredto fluidically couple to a recycle unit 14 configured to one or more ofreceive, supply, retain, transport, mix, deliver, circulate, treat,measure, and filter the antimicrobial solution. For example, in oneembodiment, the recycle unit 14 is configured to fluidically couple tothe application unit 12 at a first end to receive antimicrobial solutionfrom the application unit 12 and at a second end to deliverantimicrobial solution to the application unit 12. In normal operationof such a configuration, the antimicrobial solution is generallyrecycled through the recycle unit 14 before passing back to theantimicrobial application unit 12. At the end of an allotted time (forexample, a set number of hours, a shift, a day, or longer), processingof the meat products is halted so that the equipment can be cleaned, andthe antimicrobial solution is generally then routed through a capturevalve 16 for capture in a capture unit (not shown). After capture, theantimicrobial solution may be discarded, or processed for furtherre-use, depending on the particular application.

The antimicrobial application unit 12 includes a generally rough-likedip tank 20. The dip tank 20 is connected at either end to conveyors formoving parts through the unit 12. The dip tank 20 includes an inletsection 22, a central section 24, and an outlet section 26. A conveyor(not shown) may run along the floor of the dip tank 20. The conveyer mayinclude a moving rack, cage, hanger, or track configured to convey meatproducts through the dip tank 20. FIGS. 8 and 10 illustrate a conveyer27 according to various embodiments. The conveyer 27 runs along the diptank 20 to convey the meat products through the antimicrobial solution53 within the dip tank 20. The control unit may be configured tomaintain a preferred level 53 a of antimicrobial solution 53. Forclarity, only the portion of the conveyer 27 that extends along theinlet section 22 and through the initial portion of the central section24 is shown. However, the conveyer 27 will typically extend through thelength of the dip tank 20. The conveyer 27 is typically formed of orcoated with a noncorrosive material to limit corrosive effects of theantimicrobial solution. The conveyer 27 may include vertical flights toensure that the meat products are kept continually moving through thedip tank 20. In one embodiment, the conveyer 27 may be a polyethylenebelt, and the flights may be 3″ tall and spaced every 12″ along thebelt, although the particular form of the flights will typically beselected in consideration of the product being processed and can vary.These flights may be formed of solid pieces of polyethylene orpropylene, for example. The outlet section 24 may include a drip regionor drip pan 51 for recycling of excess antimicrobial solution. Forexample, the drip pan 51 may be positioned downstream of theantimicrobial solution 53 held in the dip tank 20 to catch excessantimicrobial solution from meat products or the conveyer that may bereleased along the outlet section 26. In one embodiment, the drip pan 51includes a drain to collect the antimicrobial solution caught in thedrip pan 51. The collected antimicrobial solution may then be recycled,e.g., returned to the bulk of the antimicrobial solution held in thedrip tank 20. The drip pan 51 may also be positioned at an angle towardthe central section 24 to direct the antimicrobial solution caught bythe drip pan 51 toward the bulk of the antimicrobial solution 53 held inthe dip tank 20. The dip tanks illustrated in FIGS. 1-10 are alsoequipped with discharge manifolds 28 a and 28 b provided on each side ofthe central section 24, and extend through apertures 29 in the sides ofthe tank 20.

With reference again to FIGS. 1-7, the recycle unit 14 includes a rotaryscreen filter 30, a rotary screen reservoir 32, a rotary screen shield34, and a cleaning unit 36 which may include a rotary screen spray bar.The interior of the rotary screen filter 30 is provided with a screwimpeller 38, and each end of the rotary screen includes a solid section40. The rotary screen filter 30 may be, for example, a 24″ diameterstainless steel drum having 1/16 inch perforated holes therein. It willbe appreciated that any suitable type and size of screen, such as a meshor different hole sizes or patterns, may be employed. The screw impeller38 may take the form of a single thread that is about 2″ high, and whichspirals around the interior of the rotary screen filter 30 to form bandsthat are about 12″ apart.

In various embodiments, the recycle unit 14 includes a rotary screenfilter 30 configured to filter solid components from recycledantimicrobial solution. For example, during application of antimicrobialsolution to workpieces solids may pass into the antimicrobial solution.The solid components may include, for example, large particles, solids,solids associated with liquids, viscous liquids, fat, gelatinousmaterial, debris, or other materials that may be filtered from theeffluent via passage through the size restrictive screen filter 30. Oneor more additional filters (not shown) may be included in theantimicrobial application system 10, particularly for removing largeparticles and solids.

The screen filter may include a body including a filter portion 30positioned between ends 40 of the body. The body may include an annularwall 31 defining a bore that extends along a rotation axis “R” aboutwhich the filter portion 30 is configured to rotate as indicated byarrow 33. In various embodiments, the filter portion 30 may beconstructed from strips of material patterned or cross-laid to form aplurality of holes or a mesh. The body 30 may also be constructed from atube or drum through which perforations are formed to define the holesof the mesh 35 between an inwardly facing surface and an outwardlyfacing surface of the annular wall 31. The screen filter 30 ispreferably coated with or formed of materials resilient to corrosion,e.g., anti-corrosives, stainless steel, synthetics, polymers, plastics,ceramics, etc. The holes of the mesh 35 may be dimensioned to obstructpassage of the solid component having a minimum size or cross-sectionwhile allowing passage of the remaining effluent. In one preferredembodiment, the holes of the mesh 35 are sized to define cross-sectionsof about 0.0625 inches, however, the mesh 35 may include smaller orlarger holes as well as fewer or additional holes, e.g., inconsideration of the amount, size, or retention characteristics thesolid components, rate or quantity of effluent, rotation rate or area ofthe filter portion, etc. In at least one embodiment, the mesh 35 of thefilter portion 30 includes holes having different sized cross-sections.

A primary pump 42 pumps clean antimicrobial solution around the system.The primary pump 42 is connected to a first distribution conduit 44,from which extend manifold distribution conduits 46 a and 46 b that areconnected to the discharge manifolds 28 a and 28 b. The distributionconduit 44 can be, for example, a 2″ diameter pipe, and a 2″ to 1″reducer can be included in the pipe close to the discharge manifolds 28a and 28 b. A further distribution conduit 47 is connected between thedistribution conduit 44 and the cleaning unit 36.

The discharge manifolds 28 a and 28 b are located underneath theexpected surface of the antimicrobial liquid in the dip tank 20, butabove the level of a conveyor belt passing through the dip tank 20. Thedischarge manifolds 28 a and 28 b shoot the antimicrobial solutionliquid across the reservoir in the dip tank 20, which helps to flip androll meat products being conveyed therethrough, and therefore unstacksthe otherwise stacked product. This allows for an even contacting of allsurfaces of the meat product with the antimicrobial solution, which isimportant to non-oxidative antimicrobial technology such as a CPC-basedsolution. As CPC has a tendency to foam, submerging the dischargemanifolds underneath the expected surface of the liquid in the dip tank20 helps to reduce foaming.

Underneath the dip tank 20 in the arrangement shown in FIG. 1, a drainconduit 54 is provided. The drain conduit 54 is the primary drain forthe dip tank 20, and will receive antimicrobial solution directly afterit has been applied to the meat products in the dip tank 20. As thissolution will contain organic solids and other particles, the drainconduit 54 may have, for example, an initial diameter of 4″ that maypass through a reducer to a 2.5″ pipe. Drain conduit 54 is connected toa solids pump 56. A recycle conduit 58 leads from the solids pump 56 tothe rotary screen filter 30, and may have, for example, a diameter of2″.

The recycle conduit 58 may include an outlet 60 adjacent to an end 40 ofthe screen filter 30 that is positioned to deliver effluent into thebore of the screen filter 30. In at least one embodiment, the recycleconduit 58 extends partially within the screen filter 30 and the outlet60 may include a downspout directed toward or positioned to deliver theeffluent to a delivery region that extends along an inwardly facingsurface of the annular wall of the screen filter 30. The delivery regionmay include a band forming one end 40 defining a perimeter of the bore.The band may be formed of the same or a different material as the filterportion 30. The band 40 may have a solid or continuous inwardly facingsurface 41 with respect to the bore. The inwardly facing surface 41 maybe smooth to discourage accumulation of solid component or fromotherwise obstructing flow of effluent from the delivery region towardthe filter portion 35. For example, the inwardly facing surface 41 mayinclude a polished metallic surface. In at least one embodiment, theinwardly facing surface 41 of the band 40 may be textured to includegrooves or projections. The grooves may be oriented to provide fluidpaths for effluent directed toward the filter portion or to breakupsolid components. In one embodiment, the inwardly facing surface 41 maybe treated or coated with a non-stick material to discourageaccumulation of solid component. In some embodiments, the absence ofholes defined in the inwardly facing surface 41 of the band 40 may alloweffluent to be delivered into the bore onto the inwardly facing surface41 while avoiding forcing accompanying solid component onto the filterportion 35 where it may become lodged. The screen filter 30 may includebands 40 positioned at both ends of the body. However, in at least oneembodiment, the screen filter 30 includes only one band 40. The screwimpeller 38 on the interior of the rotary screen filter 30 helps to movesolid particles to the other end 40 of the rotary screen filter, wherethe particles can fall out of the rotary screen filter into a collectioncontainer (not shown) for provision to a further meat processing step,for disposal, or recycling, depending on the application.

In a further embodiment, a lip or ridge may be disposed at an end of thebody of the screen filter 30 adjacent to the delivery region to preventeffluent from exiting the bore without passing onto the filter portion35. In at least one embodiment, however, the inwardly facing surface ofthe band 40 may be positioned at a raised angle with respect to thehorizontal to urge the effluent directed onto the inwardly facingsurface 41 of the band 40 toward the filter portion 35 of the screenfilter 30. The raised angle may position the inwardly facing surface 41to oppose the direction of effluent flow with respect to its releasefrom the outlet 60 to redirect the effluent toward the filter portion 35or may complement the general direction of flow of the effluent towardthe filter portion 35. In this or other embodiments, the body 35 of thescreen filter 30 may be positioned at an angle with respect to thehorizontal such that one end thereof is raised relative to the opposingend. The angle of the body 35 may further angle the inwardly facingsurface extending along the filter portion 35. Accordingly, the outlet60 of the recycle conduit 58 may be positioned to release effluent ontothe inwardly facing surface 41 at a high end of the band 40. In these orother embodiments, the outlet 60 may be angled to direct the effluentinto the bore or onto the inwardly facing surface 41 of the band 40 at aperpendicular, parallel, or other angle in-between.

As introduced above, the filter portion 35 of the screen filter 30 maybe configured to rotate about a rotation axis R as generally identifiedby arrow 33. In at least one embodiment, the body 35 of the screenfilter 30, which may include the band 40, may also be configured torotate with the filter portion 35. The rotation may be driven by anysuitable mechanism configurable to rotate the filter portion 35 of thescreen filter 30, such as gears, pulleys, motors, etc.

In at least one embodiment, the screen filter 30 includes a screwimpeller 38 configured to urge effluent through the bore. For example,the screw 38 may be configured to urge liquid portions of the effluentalong the inwardly facing surface of the annular wall of the screenfilter 30, such as the inwardly facing surface 41 of the band 40, towardthe filter portion 35. The screw 38 may also be configured to urge solidcomponents along the annular wall through the bore of the screen filter30 toward a solids trap (not shown). The solids trap may, for example,be located at an end of the body 35 where solid components may bereleased for disposal. The screw 38 may include a thread protruding fromthe annular wall toward the rotation axis R. The thread may wrap aroundthe annular wall within the bore between the ends 40 of the body 35 toform a helix therein. The thread may be directionally oriented tocomplement the rotation of the filter portion 35 to direct separatedsolid components toward an end 40 of the bore where the solid componentsmay then be passed for disposal. For example, the thread may wrap aroundthe inwardly facing surface in a clockwise or counterclockwise directionwith respect to an end 40 of the body 35 to directionally urge solidcomponents toward or away from the end 40 of the body 35 as induced bythe direction of rotation and location of the delivery region.

In various embodiments, the screen filter 30 may include or beconfigured for implementation with a cleaning unit 36. In one form, thecleaning unit 36 may be a spray bar, and may be used to clean one ormore portions of the screen filter 30, e.g., dislodge solid componentsfrom the annular wall or filter portion 35, provide additionallubrication to encourage passage or solid components through the bore,discourage accumulation of solid components on annular wall or filterportion 35, etc. The cleaning unit 36 may be equipped with a scraperconfigured to implement cleaning operations of the cleaning unit 36. Thescraper may be positioned within or outside the bore. In variousembodiments, the scraper may employ various mechanisms to scrape thescreen filter 30. For example, the scraper may include one or moreextensions such as bristles or rigid or elastomeric flaps, for example,configured to contact the inwardly or outwardly facing surfaces of theannular wall or body 35 of the filter screen 30.

In the illustrated embodiment, the cleaning unit 36 includes a spray barhaving one or more fluid ports 37 configured to direct a fluid onto theannular wall to clean the screen filter 30, e.g., to dislodge solidcomponents from the filter portion 35 or encourage solid components tomove along a lower portion of the bore of the filter screen 30 by theaction of the screw 38. In at least one embodiment, the spray bar of thecleaning unit 36 is positioned within the bore to direct fluid onto theinwardly facing surface of the annular wall, e.g., along the filterportion 35 or bands 40. In some embodiments, the cleaning unit 36includes multiple spray bars or fluid ports 37 which may also bepositioned around the body 35 or both within the bore and along theoutwardly facing surface. The fluid ports 37 may include nozzlesconfigured to directionally enhance or modulate distribution of thecleaning fluid. In certain embodiments, the fluid ports 37 may bestatically positioned. Regulation of volume or pressure of cleaningfluid directed from the fluid portions may be modulated using pumps,restriction or obstructive elements, valves, etc. For example, in oneembodiment, an orifice plate may be disposed in the cleaning unit 36.The orifice plate may be positioned to modulate flow for a single ormultiple fluid ports 37, for example. In at least one embodiment, thefluid ports 37 may be movable via a central control unit, e.g., in apredetermined or programmed pattern or selectively, which may includesensors configured to sense locations in need of the cleaning action ofthe fluid and that which send such data to the central control unit forautomated directing. In this or another embodiment, the fluid ports 37may be manually directed via remote controls provided by a user remotecontrol system incorporated with the central control unit.

A distribution conduit 47 is connected to first distribution conduit 44,and provides clean antimicrobial solution to the cleaning unit 36. Thedistribution conduit 47 may be, for example, a 1″ diameter pipe.Antimicrobial solution is filtered through the rotary screen filter 30,and falls on the flow of solid particles being impelled through therotary filter screen 30, and then out through the bottom of the filterinto the rotary screen reservoir 32.

Two outlets are provided in the rotary screen reservoir 32, and areconnected to respective conduits. A recycle conduit 50 is connected toan outlet in the bottom of the rotary screen reservoir 32, and isconnected in with the first distribution conduit 44 and primary pump 42.An overflow pipe 52 is connected to an outlet at an upper edge of therotary screen reservoir 32. Overflow pipe 52 is located generally higherthan the expected liquid level in the rotary screen reservoir, and maybe, for example, a 3″ diameter pipe. The overflow pipe 52 can bedirected to the top of dip tank 20, and does not need to include a pumpas the rotary screen reservoir 32 is positioned above the level of thedip tank 20.

In a normal work shift, the antimicrobial fluid is constantly filteredand recycled in real time, in a closed loop system, which has a highlevel of recycling efficiency that retains all of the antimicrobialsolution therein. Three capture valves 60, 62, and 64 are provided inthe conduit systems so that at the end of a shift, the antimicrobialsolution flow can be stopped and can be drained to a capture pipe 66 forcapture and further processing. It will be noted that fluid flowing intothe capture pipe 66 has been filtered by the rotary screen filter 30during both the recycle process, and the drain process. This allows thecapture line to include a finer grade of filter, such as a carbon filterwithout having to provide an additional large-scale filter.

Referring now to FIGS. 8-10, an alternative form of drainage from thedip tank 20 is shown. Instead of a drain on the bottom of the dip tank,a suction box 70 is provided to the side of the dip tank 20. The suctionbox 70 includes a box attached adjacent to an aperture 72 that is cut inthe side wall of the dip tank 20. The suction box 70 is separated fromthe dip tank 20 by a plurality of round bars 74 that act as a screen toprevent the ingress of larger pieces of meat product into the suctionbox. The bars 74 do not extend all the way to the top of the aperture72, so that fluid can flow in easily to the suction box, which enablessensors in the box to detect that a sufficient level of liquid ispresent in the dip tank. For example, a gap of 3-4″ may be left betweenthe top of the bars 74 and the top of the aperture 72. This prevents thebars 74 from becoming clogged with smaller meat particulates that mayinterfere with the operation of sensors 76 in the box, for example,pressure transducers from which the fluid level in the dip tank 20 canbe calculated. By placing the sensors in the suction box 70, they can bemore easily cleaned or replaced when needed, and by allowing for freeflow of fluid into the box 70, the sensors can measure the fluid levelin the tank 20 accurately. If needed, the suction box 70 can be brieflyseparated from the dip tank 20 using a solid plate, so that the sensorsmay be cleaned while the system is still running, and without stoppingthe conveyor 27 and bringing the processing system offline in the middleof a shift. Larger meat parts do not clog the suction box bars 74 evenwith an aperture above the bars, as the larger parts are heavier andremain on the conveyor 27, and are thus prevented from entering thesuction box (and hence the recycling conduits) by the bars 74 acting asa filter. One or more drain holes 68 are provided in the base or sidesof the suction box 70, to suction away the antimicrobial solution forfiltering.

As introduced above, the dip tank 20 illustrated in FIGS. 8 and 10 areconfigured with an outlet section 26 comprising a drip pan 51. The drippan 51 may include a downstream length of the outlet section 26 withrespect to the central section 24. The drip pan 51 may be integral withthe length of the outlet section 26 or may be provided by one or morelengths of modular drip pan extensions 55 that may be coupled to theoutlet section 26 to extend the length of the drip pan 51 along theoutlet section. The drip pan 51 is configured to catch excessantimicrobial solution that associates with the meat products orconveyer after passing through the central section 24. In thisembodiment, the drip pan 51 is positioned at an inclined angle away fromthe central section 24 to direct the excess antimicrobial solutioncaught by the drip pan 51 back toward the antimicrobial solution 53within the central section 24 of the dip tank 20. Sensors configured todetect meat products conveyed along the conveyer may be placed along theoutlet section 26. For example, in one embodiment, photo eye sensors arepositioned adjacent to the conveyer 27 to detect meat products conveyedalong the drip pan 51.

The dip tank 20 also includes a stop drip pan 57 downstream of the drippan 51. The stop drip pan 57 is configured to isolate a rinse solution,which may be applied to the meat products during a rinse application 59,from being recycled with the antimicrobial solution caught by the drippan 51 or otherwise entering the antimicrobial solution 53. The rinseapplication 59 may include one or more spray bars having spray nozzles,e.g., vee-jet nozzles for directing the rinse solution 61 onto the meatproducts after the meat products have been removed from the dip tank 20.The nozzles may be positioned to direct rinse solution 61 to completelycover the width of the conveyer and hence the meat products conveyed onthe conveyer 27. The stop drip pan 57 may include a barrier such as aprojection or gap positioned between the drip pan 51 and rinseapplication 59 configured to maintain separation of the rinse solution61 and the drip pan 51. When a gap is used, rinse solution 61 may bedirected toward the stop drip pan 57 which may include a drain forcollecting rinse solution 61 following application. In the illustratedembodiment, the stop drip pan 57 includes a length that is horizontal ordeclined with respect to the drip pan 51 or separated from the drip pan51, e.g., includes a gap, to maintain separation of the rinse solution61 from the antimicrobial solution 53. Accordingly, the stop drip pan 57may be configured to stop rinse solution 61 from diluting theantimicrobial solution 53.

The matter set forth in the foregoing description and accompanyingdrawings is offered by way of illustration only and not as a limitation.While the systems, methods, compositions, and devices for recycling ofantimicrobial solution have been described and illustrated in connectionwith certain embodiments, many variations and modifications will beevident to those skilled in the art and may be made without departingfrom the spirit and scope of the disclosure. For example, the systems,methods, compositions, and devices disclosed herein have beenidentified, adapted to, and designed for food processing use, andparticularly to processing of chicken and other poultry parts. Thosehaving skill in the art will understand upon reading the presentdisclosure that the subject matter may be applied to other processinguses. The disclosure is thus not to be limited to the precise details ofmethodology or construction set forth above as such variations andmodification are intended to be included within the scope of thedisclosure.

This specification has been written with reference to variousnon-limiting and non-exhaustive embodiments. However, it will berecognized by persons having ordinary skill in the art that varioussubstitutions, modifications, or combinations of any of the disclosedembodiments (or portions thereof) may be made within the scope of thisspecification. Thus, it is contemplated and understood that thisspecification supports additional embodiments not expressly set forth inthis specification. Such embodiments may be obtained, for example, bycombining, modifying, or reorganizing any of the disclosed steps,components, elements, features, aspects, characteristics, limitations,and the like, of the various non-limiting and non-exhaustive embodimentsdescribed in this specification. In this manner, Applicant reserves theright to amend the claims during prosecution to add features asvariously described in this specification, and such amendments complywith the requirements of 35 U.S.C. §§ 112(a) and 132(a).

What is claimed is:
 1. An antimicrobial application system, comprising:a tank comprising a liquid antimicrobial solution; a conveyor to conveyfood items through the tank, such that food items conveyed on theconveyor are dipped in the liquid antimicrobial solution; at least twodischarge nozzles for spraying liquid antimicrobial solution into thetank, wherein the discharge nozzles are positioned above the level ofthe conveyor but below a top level of the liquid antimicrobial solutionsuch that food items conveyed on the conveyor are agitated by the forceof the spray from the discharge nozzles; and a suction box comprising asensor, wherein the suction box is engaged with and in fluidcommunication with the tank, and wherein the sensor measures a level ofthe liquid antimicrobial solution in the tank.
 2. The antimicrobialapplication system according to claim 1, wherein the suction box furthercomprises: a bottom wall; at least one side wall extending from thebottom wall; one or more drain holes through the bottom wall, the atleast one side wall, or a combination thereof; and wherein the tankfurther comprises an aperture; and wherein a portion of the aperture iscovered by the at least one side wall of the suction box.
 3. Theantimicrobial application system according to claim 2, furthercomprising a filter screen disposed within the aperture.
 4. Theantimicrobial application system according to claim 3, wherein thefilter screen comprises a plurality of rods.
 5. The antimicrobialapplication system according to claim 3, wherein, the aperture has afirst height and the filter screen has a second height, wherein thefirst height is greater than the second height.
 6. The antimicrobialapplication system according to claim 2, further comprising a pump forwithdrawing the liquid antimicrobial solution through the one or moredrain holes.
 7. The antimicrobial application system according to claim2, wherein the sensor is a pressure transducer located in the bottomwall of the suction box.
 8. The antimicrobial application systemaccording to claim 2, wherein the suction box comprises three sidewalls.
 9. The antimicrobial application system according to claim 3,wherein the at least one side wall has a first height and the filterscreen has a second height, wherein the first height is greater than thesecond height.
 10. The antimicrobial application system according toclaim 1, wherein the tank further comprises: an outlet sectioncomprising a drip pan positioned to catch liquid antimicrobial solutionthat drips from the food items after the food items conveyed on theconveyor exit the liquid antimicrobial solution.
 11. The antimicrobialapplication system according to claim 10, wherein the tank furthercomprises: a stop drip pan positioned to isolate a rinse solutionapplied to the food items in a rinse application from the liquidantimicrobial solution caught by the drip pan.